US4755283A - Fluid catalytic cracking of heavy hydrocarbon oil - Google Patents
Fluid catalytic cracking of heavy hydrocarbon oil Download PDFInfo
- Publication number
- US4755283A US4755283A US06/938,450 US93845086A US4755283A US 4755283 A US4755283 A US 4755283A US 93845086 A US93845086 A US 93845086A US 4755283 A US4755283 A US 4755283A
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- US
- United States
- Prior art keywords
- heavy hydrocarbon
- surface area
- pores
- residual fraction
- hydrocarbon oil
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G11/02—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils characterised by the catalyst used
- C10G11/04—Oxides
- C10G11/05—Crystalline alumino-silicates, e.g. molecular sieves
Definitions
- This invention relates to a method for the conversion of a heavy hydrocarbon oil into a light hydrocarbon oil using a fluid catalytic cracking technique.
- FCC fluid catalytic cracking
- the heavy hydrocarbon oils contain a large amount of metals such as vanadium, nickel, iron and copper and carbon residue which cause the deactivation of the catalyst, resulting in the reduction of the yield of valuable fractions such as gasoline and light cycle oil and the increase of the yield of dry gas fractions such as hydrogen and C 2 lighter hydrocarbons and coke.
- an object of the present invention to provide a method of converting a heavy hydrocarbon oil into a light hydrocarbon oil using an FCC technique without encountering the problems of the conventional method.
- a method of cracking a heavy hydrocarbon oil containing a residual fraction with a boiling point of 538° C. or higher comprising contacting the heavy hydrocarbon oil with a fluidized bed of a particulate composite catalyst which includes an amorphous refractory inorganic oxide and a crystalline aluminosilicate dispersed in said oxide and which has a surface area distribution such that the surface area of pores having pore diameters in the range of from three times to six times the average molucular size of said residual fraction is at least 60% of the surface area of pores having pore diameters in the range of 15-150 ⁇ .
- a heavy hydrocarbon oil containing a residual fraction with a boiling point of 538° C. or higher is subjected to a fluid catalytic cracking treatment using a specific catalyst having a pore diameter distribution suitably controlled according to the average molecular size of the residual fraction.
- the catalytic conversion in the present invention is considered to proceed as follows.
- the macromolecules of the residual fraction are first cracked at acidic active sites on the amorphous refractory inorganic oxide of the catalyst to the extent that the cracked molecules can diffuse into the pores of the zeolite crystals.
- the cracked products are then further cracked within the zeolite crystals to yield gasoline and light cycle oil.
- a distillate feed stock is contacted with the catalyst at a temperature of 475°-530° C. in a reactor. Under such a reaction condition, most of the distillate is vaporized.
- the vaporized reactants whose molecular sizes are smaller than the pore diameters (7-8 ⁇ ) of the zeolite crystals, can be freely diffused through the pores of the catalyst and can diffuse into the zeolite crystals.
- the reactants which have diffused into the zeolite crystals are catalytically cracked to form mainly gasoline and light cycle oil.
- the residual fraction when the above FCC technique is applied as such to the treatment of a heavy hydrocarbon oil containing a residual fraction, the residual fraction cannot be vaporized but remains present in a liquid state. Therefore, the residual fraction cannot be freely diffused into the pores of the catalyst. Moreover, since the molecular size of the residual fraction is greater than 10 ⁇ , the molecules cannot diffuse into the zeolite crystals. As a consequence, the residual fraction is subjected to conditions as if thermally cracked in the absence of a catalyst rather than catalytically cracked, so that the formation of coke and dry gas fractions is accelerated.
- the catalyst used in the method of the present invention is a composite catalyst composed of crystalline aluminosilicate (zeolite) dispersed, generally homogeneously, in a matrix of amorphous refractory inorganic oxide. Any aluminosilicate generally used in the conventional FCC method may be suitably used in the present invention.
- the refractory inorganic oxide forming the matrix of the catalyst there may be mentioned any conventional refractory materials, such as gamma-alumina, alpha-alumina, silica, magnesia, boria, zirconia, phosphia, chromia, titania, silica-alumina, alumina-boria, alumia-phosphia and silica-magnesia.
- the content of the crystalline aluminosilicate in the catalyst is generally 5-50% by weight, preferably 15-35% by weight.
- the composite catalyst may be prepared by any known method such as described in U.S. Pat. No. 3,425,956.
- the composite catalyst should have a specific pore characteristics determined in connection with the average molecular size of the residual fraction contained in the heavy hydrocarbon oil. That is, it is essential that the surface area of pores of the catalyst having a range of pore diameters D expressed by the equation (1):
- D represents the pore diameter range ( ⁇ ) and M represents the average molecular size ( ⁇ ) of the residual fraction with a boiling point of 538° C. or higher, should be at least 60% , preferably at least 65% of the surface area of pores having pore diameters of 15-150 ⁇ in order to achieve the object of the present invention.
- the residual fraction can be relatively easily diffused into the pores having a pore diameter range of D, i.e. pore diameters in the range of from three times to six times the average molecular size of the residual fraction, and can efficiently undergo catalytic cracking.
- Pores of the catalyst which have pore diameters smaller than 3M tend to inhibit the diffusion of the residual fraction thereinto and tend to be plugged with the residual fraction.
- the catalytic cracking of the residual fraction fails to effectively proceed but, rather, the residual fraction is subjected to non-catalytic thermal cracking to form coke and dry gas fractions. Further, the light fraction with a boiling point of below 538° C. and cracked products are prevented from diffusing into the pores of the zeolite crystals.
- pores having pore diameters greater than 6M are poor in catalytic activity in cracking the residual fraction due to the decrease of surface area.
- the residual fraction tends to undergo non-catalytic thermal cracking, forming coke and dry gas fractions in a large amount.
- the particulate composite catalyst used in the method of the present invention generally has a pore volume of 0.07 ml/g or more, preferably 0.08-0.21 ml/g in pores having pore diameters of 15-150 ⁇ and a surface area of 50 m 2 /g, preferably 60-110 m 2 /g in pores having pore diameters of 15-150 ⁇ .
- the particle diameter of the composite catalyst may be that of the conventional FCC catalyst and is generally in the range of 10-150 ⁇ m.
- the heavy hydrocarbon oils to be cracked in accordance with the method of the present invention and containing a residual fraction with a boiling point of 538° C. or higher may be, for example, residual oils such as atmospheric distillation residues, vacuum distillation residues and mixtures thereof, and mixtures of the residual oils and vacuum distillate oils such as vacuum gas oils.
- the content of the residual fraction with a boiling point of 538° C. or higher in the heavy hydrocarbon oil is generally at least 5% by weight, preferably 10-70 % by weight.
- the residual fraction generally has an average molecular size of 10 ⁇ or more.
- the fluid catalytic cracking in the method of the present invention is generally performed at a temperature of 450°-550° C., preferably 480°-535° C., a pressure of 0-3 kg/cm 2 G, preferably 0.5-2 kg/cm 2 G and a weight hourly space velocity of 10-300 hour -1 , preferably 70-120 hour -1 . Details of fluid catalytic cracking are described, for instance, in Hydrocarbon Processing vol. 51, No. 9 (1972).
- pore diameter pore diameter
- surface area pore distribution
- pore distribution pore distribution
- Catalysts (A)-(D) Two kinds of heavy hydrocarbon oils (I) and (II) having the properties shown in Table 1 were subjected to thermal cracking with the use of Catalysts (A)-(D) having the compositions and properties shown in Table 2.
- Catalyst (A) is a conventional zeolite catalyst, while Catalysts (B)-(D) are composite catalysts containing zeolite dispersed in amorphous silica-alumina matrix.
- Catalysts (A)-(D) were treated with steam at 780° C. for controlling their pore structures.
- surface area is the surface area of pores having pore diameters of 15-150 ⁇ and is measured by the BET method.
- A represents the amount of a fraction in the feed stock having a boiling point of 221° C. or more and B represents the amount of a fraction in the product oil having a boiling point of 221° C. or more (except coke).
- Experiments Nos. 2 and 5 give gasoline and light cycle oil with a higher yield while reducing the production of coke as compared with the other experiments. It will be appreciated from the comparison between the results of Experiment Nos. 2 and 4 that even when the catalyst used is otherwise the same, i.e. Catalyst (B), the results are significantly inferior in the case of treatment of a feed stock whose residual fraction with a boiling point of at least 538° C. or higher has such an average molecular size that the surface area SA D of pores having a pore diameter range of D is less than 60% of the surface area SA T of pores having pore diameters in the range of 15-150 ⁇ .
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- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Crystallography & Structural Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
Abstract
Description
3M≦D≦6M (1)
TABLE 1 ______________________________________ Properties of Feed Stock Feed Stock (I) Feed Stock (II) ______________________________________ 343-538° C. Fraction (wt %) 37.5 75.0 538° C. + Fraction (wt %) 62.5 25.0 Properties of 538° C. + fraction Specific gravity (d15/4° C.) 0.945 1.02 Sulfur content (wt %) 0.3 4.8 Conradson carbon 3.2 6.3 residue (wt %) Average molecular weight 590 964 Average molecular size (Å) 10 16 ______________________________________
TABLE 2 ______________________________________ Composition and Properties of Catalysts Catalyst (A) (B) (C) (D) ______________________________________ Composition (wt %) Al.sub.2 O.sub.3 33.6 45.7 46.9 46.3 Na.sub.2 O 0.8 0.3 0.3 0.3 MgO 0.5 0.6 0.9 0.6 Fe 0.2 0.1 0.1 0.1 SiO.sub.2 balance balance balance balance Properties Surface area 92.7 86.2 86.4 86.6 (m.sup.2 /g) Apparent bulk density 0.74 0.76 0.81 0.79 (g/cc) ______________________________________
Conversion (wt %)=(B×100)/A
TABLE 3 __________________________________________________________________________ Experiment No. 1* 2 3* 4* 5 6* __________________________________________________________________________ Feed stock (I) (I) (I) (II) (II) (II) Average molecular size 10 10 10 16 16 16 of residual fraction (Å) Catalyst (A) (B) (C) (B) (D) (A) Pore diameter range D (Å) 30-60 30-60 30-60 48-96 48-96 48-96 Surface area 17 61 37 37 37 11 distribution S (%)** Results of Cracking Conversion (wt %) 76.9 75.9 76.6 77.2 77.2 69.3 Yield (wt %) Gas (C4--) 19.8 15.5 16.4 20.2 17.2 22.0 Gasoline (C5-221° C.) 44.7 51.3 47.8 43.5 50.7 35.2 Light cycle oil 10.8 15.5 13.7 8.7 12.6 8.5 (221-343° C.) Heavy cycle oil 12.3 8.6 9.7 14.1 10.2 22.2 (above 343° C.) Coke 12.4 9.1 12.4 13.5 9.3 12.1 __________________________________________________________________________ *Comparative example **S = (SA.sub.D × 100)/SA.sub.T where SA.sub.D respresents the surface area of pores with pore diameters D and SA.sub.T represents the surface area of pores with pore diameters in the range of 15-150
Claims (5)
Priority Applications (1)
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US06/938,450 US4755283A (en) | 1986-12-05 | 1986-12-05 | Fluid catalytic cracking of heavy hydrocarbon oil |
Applications Claiming Priority (1)
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US06/938,450 US4755283A (en) | 1986-12-05 | 1986-12-05 | Fluid catalytic cracking of heavy hydrocarbon oil |
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US4755283A true US4755283A (en) | 1988-07-05 |
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US06/938,450 Expired - Fee Related US4755283A (en) | 1986-12-05 | 1986-12-05 | Fluid catalytic cracking of heavy hydrocarbon oil |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1999024164A1 (en) * | 1997-11-11 | 1999-05-20 | Solvay (Societe Anonyme) | Process for producing spherical catalyst particles, catalyst particles and their use in a chemical synthesis |
US5961817A (en) * | 1996-10-15 | 1999-10-05 | Exxon Research And Engineering Company | Mesoporous FCC catalyst formulated with gibbsite |
US6022471A (en) * | 1996-10-15 | 2000-02-08 | Exxon Research And Engineering Company | Mesoporous FCC catalyst formulated with gibbsite and rare earth oxide |
Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3425956A (en) * | 1964-03-26 | 1969-02-04 | Grace W R & Co | Process for preparing molecular sieve containing cracking catalysts |
US3912619A (en) * | 1972-08-21 | 1975-10-14 | Grace W R & Co | Preparation of cracking catalyst |
US3944482A (en) * | 1973-08-08 | 1976-03-16 | Gulf Research & Development Company | Process for the cracking of high metals content feedstocks |
US4217240A (en) * | 1976-09-02 | 1980-08-12 | E. I. Du Pont De Nemours And Company | Stable aluminosilicate aquasols having uniform size particles and their preparation |
US4257874A (en) * | 1977-08-31 | 1981-03-24 | E. I. Du Pont De Nemours And Company | Petroleum refinery processes using catalyst of aluminosilicate sols and powders |
US4310441A (en) * | 1977-02-16 | 1982-01-12 | Filtrol Corporation | Large pore silica-alumina gels and method of producing the same |
US4362651A (en) * | 1979-03-22 | 1982-12-07 | Schwarzenbek Eugene F | High porosity catalysts |
US4457833A (en) * | 1981-08-27 | 1984-07-03 | Ashland Oil, Inc. | Process and catalyst for the conversion of carbo-metallic containing oils |
US4624773A (en) * | 1983-08-16 | 1986-11-25 | Ashland Oil, Inc. | Large pore catalysts for heavy hydrocarbon conversion |
-
1986
- 1986-12-05 US US06/938,450 patent/US4755283A/en not_active Expired - Fee Related
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3425956A (en) * | 1964-03-26 | 1969-02-04 | Grace W R & Co | Process for preparing molecular sieve containing cracking catalysts |
US3912619A (en) * | 1972-08-21 | 1975-10-14 | Grace W R & Co | Preparation of cracking catalyst |
US3944482A (en) * | 1973-08-08 | 1976-03-16 | Gulf Research & Development Company | Process for the cracking of high metals content feedstocks |
US4217240A (en) * | 1976-09-02 | 1980-08-12 | E. I. Du Pont De Nemours And Company | Stable aluminosilicate aquasols having uniform size particles and their preparation |
US4310441A (en) * | 1977-02-16 | 1982-01-12 | Filtrol Corporation | Large pore silica-alumina gels and method of producing the same |
US4257874A (en) * | 1977-08-31 | 1981-03-24 | E. I. Du Pont De Nemours And Company | Petroleum refinery processes using catalyst of aluminosilicate sols and powders |
US4362651A (en) * | 1979-03-22 | 1982-12-07 | Schwarzenbek Eugene F | High porosity catalysts |
US4457833A (en) * | 1981-08-27 | 1984-07-03 | Ashland Oil, Inc. | Process and catalyst for the conversion of carbo-metallic containing oils |
US4624773A (en) * | 1983-08-16 | 1986-11-25 | Ashland Oil, Inc. | Large pore catalysts for heavy hydrocarbon conversion |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5961817A (en) * | 1996-10-15 | 1999-10-05 | Exxon Research And Engineering Company | Mesoporous FCC catalyst formulated with gibbsite |
US6022471A (en) * | 1996-10-15 | 2000-02-08 | Exxon Research And Engineering Company | Mesoporous FCC catalyst formulated with gibbsite and rare earth oxide |
WO1999024164A1 (en) * | 1997-11-11 | 1999-05-20 | Solvay (Societe Anonyme) | Process for producing spherical catalyst particles, catalyst particles and their use in a chemical synthesis |
US6465382B1 (en) | 1997-11-11 | 2002-10-15 | Solvay (Societe Anonyme) | Process for producing spherical catalyst particles, catalyst particles and their use in a chemical synthesis |
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Owner name: CHIYODA CHEMICAL ENGINEERING & CONSTRUCTION, CO., Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNORS:HASHIMOTO, HIDEO;TAKATSUKA, TORU;SATOH, SHUZO;AND OTHERS;REEL/FRAME:004976/0228 Effective date: 19861127 Owner name: CHIYODA CHEMICAL ENGINEERING & CONSTRUCTION, CO., Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HASHIMOTO, HIDEO;TAKATSUKA, TORU;SATOH, SHUZO;AND OTHERS;REEL/FRAME:004976/0228 Effective date: 19861127 |
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